Stain repellent and voc eliminating coatings and use thereof

ABSTRACT

A coating dispersion or building article can include titanium dioxide, and a dihydrazide. The coating dispersion or building article can further include calcium carbonate, calcined aluminum silicate, acrylic polymers, and a fluoroalkyl polymer.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application is a continuation of U.S. patent applicationSer. No. 14/503,011, filed Sep. 30, 2014, entitled “STAIN REPELLENT ANDVOC ELIMINATING COATINGS AND USE THEREOF,” naming inventors Darran L.Martin and Alan L. Boyd, and claims priority under 35 U.S.C. § 119(e) toU.S. Patent Application No. 61/884,933, filed Sep. 30, 2013, entitled“STAIN REPELLENT AND VOC ELIMINATING COATINGS AND USE THEREOF,” naminginventors Darran L. Martin and Alan L. Boyd, filed Sep. 30, 2013, ofwhich both are assigned to the current assignee hereof and incorporatedherein by reference in their entireties.

FIELD OF THE DISCLOSURE

The invention relates to a building article having stain repellentcoatings and containing a dihydrazide as an agent capable of trappingformaldehyde.

BACKGROUND

Highly varied composite materials are used in construction of dwellings,schools, hospitals, and offices, as well as of transportation vehicles.Some of these materials, such as sound and/or thermal insulators, woodenpanels, furniture parts and decorative parts, use adhesives, paints andvarnishes comprising formaldehyde-based resins. The proportion of freeformaldehyde in these materials is kept at a very low level owing to theincorporation of a small amount of agents capable of trappingformaldehyde.

Moreover, in public places, schools, and hospitals, the panels, boards,and furniture parts are held in white or off white colors which requirethat they can be easily cleaned. Accordingly coatings that haveacceptable stain repellency are in demand.

However, regulations regarding protection against undesirable emissionsof products, such as formaldehyde, which may exhibit a risk to thehealth of the individual are becoming stricter and require a furtherreduction in the amount of free formaldehyde present in materials orcapable of being emitted by materials over time.

Accordingly, there is a need for building and construction material thatcomply with the demanding regulation and are easily to clean.

SUMMARY

To achieve this aim, the present invention provides a stain repellentcoating that at least one dihydrazide. A coating dispersion or buildingarticle can include titanium dioxide, and a dihydrazide. The coatingdispersion or building article can further include calcium carbonate,calcined aluminum silicate, acrylic polymers, and a fluoroalkyl polymer.

DETAILED DESCRIPTION

A dihydrazide in accordance with the present invention corresponds tothe following formula:

H₂N—NH—CO—R—CO—NH—NH₂

in which R represents a linear or branched alkylene radical preferablycontaining 1 to 18 carbon atoms, optionally substituted by one or morehydroxyl radicals; or an arylene, preferably phenylene or biphenylene,radical optionally substituted by one or more hydroxyl radicals, one ormore halogen atoms, especially F, Cl or Br, or one or more linear orbranched alkyl radicals containing 1 to 4 carbon atoms.

Advantageously, the dihydrazide is chosen from the dihydrazides forwhich the radical R is a C₁-C₁₂, preferably C₁-C₈ alkylene radical. Thepreferred dihydrazide is adipic acid dihydrazide. In embodiments, theamount of dihydrazide represents 0.1 to 20 wt %, such as 0.2 to 10 wt %,or 0.3 to 5 wt % of the coating.

In embodiments, the dihydrazide is present in coatings having stain andwater repellency. Such properties can be achieved by mixing in apolymeric material into the dispersion. As examples, polymeric materialsthat may be used are polyolefin, for example of polyethylene, ofpolypropylene, of polyisobutylene and of polymethylpentene, of polyvinylacetate (homopolymer or copolymer), for example of ethylene/vinylacetate (EVA), of polyvinyl alcohol (homopolymer or copolymer), forexample of ethylene/vinyl alcohol, of polylactic acid, of acrylonitrile,for example modacrylic (containing 35 to 85% of acrylonitrile units), ofpolyoxyalkylene, for example of polyoxyethylene, of polyoxyphenylene, ofpolyacrylic or of polyacrylate, for example of polymethyl methacrylate(PMMA), of polyester, especially of polyalkylene terephthalate, forexample of polyethylene terephthalate and polybutylene terephthalate, ofpolyamide, of polyimide, of chlorinated and/or fluorinated polymer, forexample of polyvinyl chloride, of polychiorofluoroethylene, ofperfluoroethylene and of perfluoropropylene, of polysulfone, for examplepolyethersulfone, of polyurethane, especially elastane (at least 85% ofthermoplastic polyurethane elastomer), of polybenzimidazole and ofaramid.

Other polymers, that can be used are thermoplastic polymers, for examplestyrene/acrylonitrile, acrylonitrile/butadiene/styrene, cellulose(tri)acetate, expanded polystyrene, a polyolefin such as polyethyleneand polypropylene, a poly(meth)acrylate, a polyvinyl acetate or apolyoxymethylene; a thermosetting polymer, for example an unsaturatedpolyester, an epoxide, a phenolic resin such as a novolac or a resol, inparticular having a content of free aldehyde(s) of less than 0.05%, apolyimide, a polyurethane, a phenoplast or a biopolymer, for example apolysaccharide or a protein; an elastomeric polymer, for example afluoropolymer, in particular based on vinylidene fluoride, neoprene, apolyacrylic, a polybutadiene, a polyether amide, a silicone, a naturalrubber or styrene-butadiene rubber (SBR), or a biopolymer, for example apolysaccharide or a protein.

The polymers can be present in an amount from 2 to 30 wt %, such as 5 to25 wt %, or 10 to 25 wt % of the coating.

In order to achieve stain repellency, the coating of interest caninclude fluoropolymers. Such fluoropolymers includepolytetrafluoroethylene (PTFE), tetrafluoroethylene-hexafluoropropylene(FEP), modified tetrafluoroethylene-hexafluoropropylene (mFEP),perfluoroalkoxyethylene (PFA), modified perfluoroalkoxyethylene (mPFA),ethylene-tetrafluoroethylene (ETFE), tetrafluoro-ethylene-perfluoro(methyl vinyl ether) (MFA), modified polytetrafluoroethylene (TFM),polyvinylidene fluoride (PVDF), ethylene-chlorotrifluoroethylene(ECTFE), and combination thereof.

The fluoropolymer can be present in an amount of at least 0.1 to 5 wt %,0.2 to 4 wt %, or 0.3 to 3 wt %.

Another aspect of the present disclosure is to provide a stain repellentcoating in wall and ceiling coverings. A ceiling tile having such stainrepellency is more efficiently prevented from getting dirty duringinstallation or use. Moreover, it is an object to provide a method formounting an improved suspended ceiling.

A further object of the present invention is to provide an improvedceiling tile which is adapted to be mounted in a grid of profilesforming a frame which supports the ceiling tile. The ceiling tile has afirst and a second pair of non-adjacent side-edge portions, wherein thegrid of profiles engage from below with the first pair of side-edgeportions, and wherein the grid of profiles engage from above with thesecond pair of side-edge portions. The grid of profiles engages withsaid first and second pair of side-edge portions such that a clampingaction that counteracts lateral displacement of the ceiling tile isprovided. The ceiling tile has further a coating as described herein.

An advantage of the present inventive concept is that the ceiling tileis prevented from getting dirty or stained during installation employinga locking system that secures the tile to a suspended frame. The ceilingtile includes side-edge portion of the ceiling tile may be a part of anunderside of the ceiling tile, a part of an upper side of the ceilingtile, a groove or cavity provided in a side portion of the ceiling tile,a protrusion provided in a side portion of the ceiling tile, etc.

In particular, there is reduced cleaning requirement for the ceilingsince any part of the suspended ceiling comprising the coating. Thus, ina mounted state the ceiling tiles comprised in the inventive suspendedceiling are more efficiently prevented from involuntary staining whichmay be caused by a wind uplift, impacts from objects, forces applied tothe ceiling panel from below, e.g. during a cleaning process, a suddenchange of air pressure in the room when a door connected to the room isabruptly opened, etc.

By means of the clamping action, or frictional fit, the ceiling tile canbe fixed in a lateral position, being restrained by friction.Preferably, the clamping action is such that the ceiling tile is keptfixed at least in a first lateral direction. More preferably, theclamping action is such that the ceiling tile is kept fixed in twoperpendicular lateral directions.

The following represents an exemplary list of embodiments in accordancewith the invention:

Item 1. A coating dispersion, the coating dispersion comprising:

-   -   water;    -   titanium dioxide;    -   calcium carbonate;    -   calcined aluminum silicate;    -   acrylic polymers;    -   a dihydrazide; and    -   a fluoroalkyl polymer.

Item 2. The coating dispersion according to item 1, wherein the amountof titanium dioxide is at least 5 wt %, at least 6 wt %, or at least 7wt %, and not greater than 15 wt %, not greater than 12 wt %, or notgreater than 10 wt %.

Item 3. The coating dispersion according to item 1, wherein the amountof calcium carbonate is at least 18 wt %, at least 23 wt %, or at least28 wt %, and not greater than 35 wt %, not greater than 32 wt %, or notgreater than 30 wt %.

Item 4. The coating dispersion according to item 1, wherein the amountof calcined aluminum silicate is at least 5wt %, at least 6wt %, or atleast 7 wt %, and not greater than 12 wt %, not greater than 10 wt %, ornot greater than 8 wt %.

Item 5. The coating dispersion according to item 1, wherein the amountof acrylic polymers is at least 7 wt %, at least 10 wt %, or at least 13wt %, and not greater than 20 wt %, not greater than 17 wt %, or notgreater than 14 wt %.

Item 6. The coating dispersion according to item 1, wherein the amountof the dihydrazide is at least 0.1 wt %, at least 0.15 wt %, or at least0.18 wt %, and not greater than 0.5 wt %, not greater than 0.4 wt %, ornot greater than 0.3 wt %.

Item 7. The coating dispersion according to item 1, wherein the amountof the a fluoroalkyl polymer is at least 0.2 wt %, or at least 0.3 wt %,at least 0.35 wt %, and not greater than 0.9 wt %, not greater than 0.7wt %, or not greater than 0.4 wt %.

Item 8. The coating dispersion according to any of the foregoing items,further comprising at least one ingredient selected from the group ofMagnesium silicate, anhydrous aluminum silicate, or a mixture thereof.

Item 9. The coating dispersion according to item 8, wherein the at leastone ingredient is present in an amount of at least 2 wt %, at least 4 wt%, or at least 6 wt %, and not greater than 12 wt %, not greater than 10wt %, or not greater than 8 wt %.

Item 10. The coating dispersion according to any of the foregoing items,further comprising zinc oxide.

Item 11. The coating dispersion according to item 10, wherein the zincoxide is present in an amount of at least 0.2 wt %, at least 0.4 wt %,or at least 0.6 wt %, and not greater than 1.2 wt %, not greater than 1wt %, or not greater than 0.8 wt %.

Item 12. A building article comprising a coating, wherein the coatingincludes:

-   -   titanium dioxide, calcium carbonate, calcined aluminum silicate,        acrylic polymers, a dihydrazide, and a fluoroalkyl polymer.

Item 13. The building article according to item 12, wherein the amountof calcium carbonate is at least 25 wt %, at least 30 wt %, or at least35 wt %, and not greater than 55 wt %, not greater than 50 wt %, or notgreater than 45 wt %.

Item 14. The building article according to item 12, wherein the amountof titanium dioxide is at least 6 wt %, at least 8 wt %, or at least 10wt %, and not greater than 16 wt %, not greater than 14 wt %, or notgreater than 12 wt %.

Item 15. The building article according to item 12, wherein the amountof calcined aluminum silicate is at least 6 wt %, at least 8 wt %, or atleast 10 wt %, and not greater than 16 wt %, not greater than 14 wt %,or not greater than 12 wt %.

Item 16. The building article according to item 12, the amount ofacrylic polymers is at least 10 wt %, at least 15 wt %, or at least 18wt %, and not greater than 30 wt %, not greater than 25 wt %, or notgreater than 22 wt %.

Item 17. The building article according to item 12, wherein the amountof the dihydrazide is at least 0.15 wt %, at least 0.2 wt %, or at least0.25 wt %, and not greater than 0.6 wt %, not greater than 0.5 wt %, ornot greater than 0.4 wt %.

Item 18. The building article according to item 12, the amount of the afluoroalkyl polymer is at least 0.2 wt %, or at least 0.3 wt %, at least0.35 wt %, and not greater than 1 wt %, not greater than 0.8 wt %, ornot greater than 0.6 wt %.

Item 19. The building article according to item 12 further comprising atleast one ingredient selected from the group of Magnesium silicate,anhydrous aluminum silicate, or a mixture thereof.

Item 20. The building article according to item 19, wherein the at leastone ingredient is present in an amount of at least 2 wt %, at least 4 wt%, or at least 6 wt %, and not greater than 20 wt %, not greater than 16wt %, or not greater than 12 wt %.

Item 21. The building article according to item 12, further comprisingzinc oxide.

Item 22. The building article according to item 22, wherein the zincoxide is present in an amount of at least 0.5 wt %, at least 0.7 wt %,or at least 0.9 wt %, and not greater than 2 wt %, not greater than 1.5wt %, or not greater than 1.2 wt %.

Item 23. The coating dispersion or building article according to any oneof the preceding items, wherein the dihydrazide is selected fromisophthalic dihydrazide, sebacic dihydrazide, adipic dihydrazide, or anycombination thereof.

Item 24. The building article according to any one of items 12-24,wherein the building article includes a tile, a mineral board, a gypsumboard, fiberglass, or any combination thereof.

Item 25. The building article according to any one of items 12-24,wherein coating has a thickness of at least 1 mil, at least 2 mils, orat least 3 mils, and not more than 6 mils, 5 mils, or 4 mils.

The following example makes it possible to illustrate the inventionwithout however limiting it.

EXAMPLE 1

a) Preparing a Coating Dispersion

Into a container, 1563.04 g of water, 10.4 g of adipic acid dihydrazide,2.4 g of Surfynol (surfactant), 5.6 g of hydro-cracked parafinnic oil(90%), 2.3 g of sodium polyacrylate emulsion (43%), 395 g of titaniumdioxide, 1410 g of precipitated calcium carbonate, 160g of Magnesiumsilicate, 350 g of calcined aluminum silicate, 150 g of anhydrousaluminum silicate (calcined kaolin), 674 g of acrylic polymers, 71.6 gof zinc oxide dispersion (50 wt %), 95 g of fluoroalkyl methacrylatecopolymer, and 27.4 g of polyethylene acrylate mixture are mixed. Themixture was painted on a gypsum board panel and air-dried.

b) Compliance Test

A panel having the coating was submitted to berkeley analytical for VOCEmission testing in accordance with California Department of PublicHealth standard CDPH/EHLB/Standard Method V1.1-2010. The result was thepanel was complain to School classroom and private office criteria withformaldehyde amounts at less than 9 micrograms/m³.

c) Stain Removal

Stain Removal was conducted according to ASTM Standard D4828 usingmethod reference 8.7 and 8.4 on an actual panel Tables 1-3 show theresults.

TABLE 1 Rating <100 double rubs Rating <100 double rubs Stain/SoilBleach soln. Quat NH soln. Betadine (H brand) 10 10 Mustard (French's) 33 Cola (Coca Cola) 10 10 Coffee (Starbucks) 5 5 Ketchup (Heinz) 10 10

TABLE 2 Rating <100 double rubs Rating <100 double rubs Stain/Soil EtOHsoln. Peroxide soln. Betadine (H brand) 10 10 Mustard (French's) 3 3Cola (Coca Cola) 10 10 Coffee (Starbucks) 5 5 Ketchup (Heinz) 10 10 0:No change from original intensity (depth) of soil or stain, 3: Slightchange from original, but readily visible, 5: Moderate change fromoriginal, slightly visible, 7: Large change from original, barelyvisible, and 10: All soil and stain removed.

TABLE 3 1000 wash 2000 wash 5000 cycles cycles 2500 wash cycles washcycles Gloss change N N N/I I Color change N N N SD Erosion N S S SGloss Change N—None I—Increase II—Large increase D—Decrease DD—Largedecrease Color Change N—None SD—Slightly darker CD—Considerably darkerSL—Slightly lighter CL—Considerably lighter Erosion N—None S—SlightM—Moderate

What is claimed is:
 1. A coating dispersion, the coating dispersioncomprising: water; titanium dioxide; calcium carbonate; calcinedaluminum silicate; acrylic polymers; a dihydrazide; and a fluoroalkylpolymer present at up to 5 wt % of the coating dispersion.
 2. Thecoating dispersion according to claim 1, wherein the amount of titaniumdioxide is at least 5 wt % of the coating dispersion.
 3. The coatingdispersion according to claim 2, wherein the amount of titanium dioxideis not greater than 15 wt % of the coating dispersion
 4. The coatingdispersion according to claim 1, wherein the amount of calcium carbonateis at least 18 wt % of the coating dispersion.
 5. The coating dispersionaccording to claim 4, wherein the amount of calcium carbonate is notgreater than 35 wt % of the coating dispersion
 6. The coating dispersionaccording to claim 1, wherein the amount of calcined aluminum silicateis at least 5 wt % of the coating dispersion.
 7. The coating dispersionaccording to claim 6, wherein the amount of calcined aluminum silicateis not greater than 12 wt % of the coating dispersion.
 8. The coatingdispersion according to claim 1, wherein the amount of acrylic polymersis at least 7 wt % of the coating dispersion.
 9. The coating dispersionaccording to claim 8, wherein the amount of acrylic polymers is notgreater than 20 wt % of the coating dispersion.
 10. The coatingdispersion according to claim 1, wherein the amount of the dihydrazideis at least 0.1 wt % of the coating dispersion.
 11. The coatingdispersion according to claim 10, wherein the amount of the dihydrazideis not greater than 0.5 wt % of the coating dispersion.
 12. The coatingdispersion according to claim 1, wherein the amount of the fluoroalkylpolymer is 0.1 wt % to 5 wt % of the coating dispersion.
 13. The coatingdispersion according to claim 1, further comprising at least oneingredient selected from the group of Magnesium silicate, anhydrousaluminum silicate, or a mixture thereof of the coating dispersion. 14.The coating dispersion according to claim 13, wherein the at least oneingredient is present in an amount of at least 2 wt % of the coatingdispersion.
 15. The coating dispersion according to claim 13, whereinthe at least one ingredient is present in an amount of not greater than12 wt % of the coating dispersion.
 16. The coating dispersion accordingto claim 1, further comprising zinc oxide.
 17. The coating dispersionaccording to claim 16, wherein the zinc oxide is present in an amount ofat least 0.2 wt % of the coating dispersion.
 18. The coating dispersionaccording to claim 17, wherein the zinc oxide is present in an amount ofnot greater than 1.2 wt % of the coating dispersion.
 19. A buildingarticle comprising the coating dispersion of claim
 1. 20. The buildingarticle according to claim 19, wherein the building article includes atile, a mineral board, a gypsum board, fiberglass, or any combinationthereof.